Method for rapid encapsulation of a corner gap defined within a corner of a door panel for an appliance

ABSTRACT

A method of forming an insulated door panel includes folding side flanges of a metallic sheet to define side edges of a structural outer panel that extend from a front panel. A gap is defined between each set of adjacent side edges. Interior blocks are secured to an interior of the structural outer panel proximate each gap to define adhesive cavities. Exterior blocks are positioned at an exterior surface of the structural outer panel at each gap to further define the adhesive cavities. An adhesive is disposed within each adhesive cavity and is contained therein by the interior and exterior blocks. The adhesive is cured to a solid sealing member that adheres the interior blocks to the interior surface of the structural outer panel to form a sealed structural panel. The exterior blocks are removed and each solid sealing member defines a hermetic seal at each gap.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 17/307,084, filed May 4, 2021, entitled METHOD FOR RAPIDENCAPSULATION OF A CORNER GAP DEFINED WITHIN A CORNER OF A DOOR PANELFOR AN APPLIANCE, now U.S. Pat. No. 11,402,148, which is a continuationof U.S. patent application Ser. No. 16/308,965, filed Dec. 11, 2018,entitled METHOD FOR RAPID ENCAPSULATION OF A CORNER GAP DEFINED WITHIN ACORNER OF A DOOR PANEL FOR AN APPLIANCE, now U.S. Pat. No. 11,029,077,which is a national stage entry of PCT/US2017/019930 filed Feb. 28,2017, entitled METHOD FOR RAPID ENCAPUSLATION OF A CORNER GAP DEFINEDWITHIN A CORNER OF A DOOR PANEL FOR AN APPLIANCE, the entire disclosuresof which are hereby incorporated herein by reference.

FIELD OF THE DEVICE

The device is in the field of cabinet structures for appliances, andmore specifically, a rapid encapsulation system used for sealing a gapat corners of a door panel for an appliance.

SUMMARY

In at least one aspect, a method of forming an insulated door panel foran appliance includes steps of folding side flanges of a metallic sheetto define side edges of a structural outer panel, wherein the side edgesextend from a front panel and wherein a gap is defined between each setof adjacent side edges. Interior blocks are secured to an interiorsurface of the structural outer panel and proximate each respective gapto define an adhesive cavity at each respective gap. Exterior blocks arepositioned at an exterior surface of the structural outer panel and ateach respective gap to further define the adhesive cavity at eachrespective gap. An adhesive is disposed within each adhesive cavity,wherein the adhesive substantially fills each gap and is contained inthe adhesive cavities by the interior and exterior blocks. The adhesiveis cured to form a solid sealing member within each adhesive cavity thatadheres the respective interior block to the interior surface of thestructural outer panel to form a sealed structural panel. The exteriorblocks are removed from the exterior surface of the structural outerpanel, wherein each solid sealing member defines a hermetic seal at eachrespective gap. A back panel is disposed onto the side edges of thestructural outer panel, wherein the back panel, structural outer panel,and the solid sealing member define an insulating cavity therein.

In at least another aspect, a method for forming a vacuum insulatedstructure includes steps of folding a metallic sheet to define a frontpanel and side edges of a structural outer panel, wherein a gap isdefined between each set of adjacent side edges. Interior blocks aredisposed proximate each respective gap to define an adhesive cavity ateach respective gap. Exterior blocks are disposed proximate eachrespective gap, wherein each exterior block is temporarily engaged witha respective set of adjacent side edges and further defines the adhesivecavity at the gap. An adhesive is disposed within each adhesive cavity,wherein the adhesive substantially fills each gap. The adhesive is curedto define a cured adhesive that adheres to the respective interior blockand an interior surface of the structural outer panel. The exteriorblocks are removed from an exterior surface of the structural outerpanel, wherein the cured adhesive seals each gap defined between eachset of adjacent side edges.

In at least another aspect, a method for forming a vacuum insulatedstructure for an appliance door includes folding a metallic sheet toform a structural outer panel that includes a plurality of side edgesand a gap between each set of adjacent side edges. Interior blocks aredisposed proximate an interior surface of the structural outer panel todefine respective adhesive cavities. A temporary exterior dam isdisposed at each gap, wherein each gap is positioned within one of theadhesive cavities. An adhesive is disposed within each adhesive cavity.The adhesive is cured to define a cured adhesive that occupies each gapwithin each respective adhesive cavity. Each temporary exterior dam isremoved from an exterior surface of the structural outer panel, whereinthe cured adhesive hermetically seals each gap.

These and other features, advantages, and objects of the present devicewill be further understood and appreciated by those skilled in the artupon studying the following specification, claims, and appendeddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a front elevational view of an appliance incorporating anaspect of the rapid encapsulation system for sealing the corners of thedoor panels;

FIG. 2 is a top plan view of a metallic sheet having a plurality of sideflanges shown in an unfolded state;

FIG. 3 is the metallic sheet of FIG. 2 shown in the folded state todefine the structural outer panel;

FIG. 4 is a top plan view of a structural outer panel showing theinterior blocks positioned at each respective gap and the exteriorblocks being moved into position proximate each respective gap;

FIG. 5 is a top plan view of the structural outer panel of FIG. 4showing the inner and outer blocks positioned proximate each respectivegap and showing an adhesive within each adhesive cavity defined betweenthe interior and exterior blocks;

FIG. 6 is a top plan view of the structural outer panel of FIG. 5showing the adhesive in a cured state and the exterior blocks removed;

FIG. 7 is a top plan view of an alternate aspect of the structural outerpanel showing the interior blocks positioned at the gap and the outerblocks being moved by a mechanical assembly to engage each respectivegap;

FIG. 8 is a top plan view of the structural outer panel of FIG. 7showing the exterior blocks placed in position of each respective gap;

FIG. 9 is a top plan view of the structural outer panel of FIG. 8showing adhesive being deposited within each adhesive cavity defined bythe interior and exterior blocks;

FIG. 10 is a top plan view of the structural outer panel of FIG. 9showing the exterior blocks being removed and showing the adhesive in acured state;

FIG. 11 is a schematic flow diagram illustrating a method for forming aninsulated door panel for an appliance;

FIG. 12 is a schematic flow diagram for illustrating a method forforming structural outer panel for an appliance; and

FIG. 13 is a schematic flow diagram illustrating a method for forming astructural outer panel for a door of an appliance.

DETAILED DESCRIPTION OF EMBODIMENTS

For purposes of description herein the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the device as oriented in FIG. 1 . However, itis to be understood that the device may assume various alternativeorientations and step sequences, except where expressly specified to thecontrary. It is also to be understood that the specific devices andprocesses illustrated in the attached drawings, and described in thefollowing specification are simply exemplary embodiments of theinventive concepts defined in the appended claims. Hence, specificdimensions and other physical characteristics relating to theembodiments disclosed herein are not to be considered as limiting,unless the claims expressly state otherwise.

As illustrated in FIGS. 1-6 , reference numeral 10 generally refers to astructural outer panel that can be used in a door panel 12 for anappliance 14. According to the various embodiments, the structural outerpanel 10 can be made from a metallic sheet 16 that is bent into theshape of the structural outer panel 10 that includes a front panel 18and a plurality of side edges 20 that extend back from the front panel18. Because the side edges 20 are folded to be substantiallyperpendicular to the front panel 18, a series of gaps 22 can be definedbetween each set of adjacent side panels of the structural outer panel10. In order to seal these gaps 22, a sealing adhesive 24 is disposed ateach gap 22 so that an insulating material 26 can be disposed within aninsulating cavity 28 at least partially defined by the structural outerpanel 10. By placing the sealing adhesive 24 at each gap 22, each gap 22is thereby hermetically sealed. After the entire structure of the doorpanel 12 is formed, gas 30 can be expressed, expelled, or otherwiseremoved from the insulating cavity 28 within the door panel 12 to definea vacuum insulated structure 32. With the sealing adhesive 24 at each ofthe gaps 22, gas 30 and vapor are substantially prevented frompermeating into the insulating cavity 28 via the now-sealed gaps 22within the structural outer panel 10.

Referring again to FIGS. 1-6 , in order to maintain the position of thesealing adhesive 24 during curing, it is contemplated that a series ofinterior blocks 34 can be secured, attached, adhered, or otherwisedisposed against two of the side edges at an interior surface 36 of thestructural outer panel 10 proximate each respective gap 22. In thismanner, the interior blocks 34 remain adhered to the interior surface 36of the structural outer panel 10 at two adjacent side edges to define anadhesive cavity 38 that receives the adhesive 24 in an uncured state 40.After the adhesive 24 defines a cured state 42 to form the solid sealingmember 44, the interior blocks 34 remain in place during the life of theappliance 14 and supplement the hermetic sealing capability of the solidsealing member 44. It is contemplated that the sealing adhesive 24 canbe a fast-curing adhesive 24 that is held in place during the curingprocess by the interior blocks 34, the interior surface 36 of thestructural outer panel 10 and also temporarily positioned exteriorblocks 70 that are set against the exterior surface 72 of the structuralouter panel 10.

According to the various embodiments, the door panel 12 thatincorporates the sealing adhesive 24 within each gap 22 of thestructural outer panel 10 can be used in various configurations. By wayof example, and not limitation, the structural outer panel 10 can beformed for use as a door panel 12, a drawer panel 50, a sliding panel, astructural cabinet 52, or other similar structural member within which avacuum may be defined. The structural outer panel 10 can also be usedwithin various appliances 14. Such appliances 14 can include, but arenot limited to, refrigerators, freezers, coolers, hot water heaters,dishwashers, laundry appliances, combinations thereof, and other similarhousehold and commercial appliances and fixtures.

Referring now to FIGS. 1-6 and 11 , having described various aspects ofthe structural outer panel 10 that is formed from the folded metallicsheet 16, a method 400 is disclosed for forming an insulated door panel12 for an appliance 14. According to the method 400, side flanges 60 ofthe metallic sheet 16 are folded to define side edges 20 of a structuralouter panel 10 (step 402). In the unfolded state 62, it is contemplatedthat the side flanges 60 can be co-planar with a front panel 18 of themetallic sheet 16. Once folded, the side flanges 60 define side edges 20of the structural outer panel 10 that extend substantially perpendicularfrom the front panel 18. In this manner, a series of gaps 22 are definedbetween each set of adjacent side edges 20 of the structural outer panel10. After the structural outer panel 10 is formed, interior blocks 34are secured to an interior surface 36 of the structural outer panel 10and proximate each respective gap 22 (step 404). Securing or otherwisedisposing the interior blocks 34 proximate the gap 22 serves to at leastpartially define an adhesive cavity 38 at each respective gap 22.According to the various embodiments, it is contemplated that theinterior blocks 34 can be attached, adhered, fastened or otherwisesecured to the interior surface 36 of the structural outer panel 10. Inthis manner, the interior blocks 34 are designed to be permanently leftwithin the structural outer panel 10 after the formation of the doorpanel 12 for the appliance 14.

Referring again to FIGS. 1-6 and 11 , in order to complete the adhesivecavity 38, exterior blocks 70 are positioned or otherwise disposed at anexterior surface 72 of the structural outer panel 10 and at eachrespective gap 22 (step 406). By positioning the exterior blocks 70 atthe exterior surface 72, portions of the side flanges 60 are held inplace between the interior and exterior blocks 34, 70 at each gap 22. Inthis manner, adjacent side flanges 60 at each gap 22 are held in placebetween the interior and exterior blocks 34, 70 such that the gap 22 issubstantially minimized to define a seam 74 between adjacent side edges20 of the structural outer panel 10. The formation of the minimal seam74 serves to minimize the appearance of the adhesive 24 in the curedstate 42 within the gap 22 such that the final seam 74 has an appearanceof being defined only by the side edges 20 of the structural outer panel10. In this manner, no welding or additional fasteners may be necessaryin order to seal and secure the adjacent side edges 20 of the structuralouter panel 10 to define the minimal seam 74.

Referring again to FIGS. 1-6 and 11 , after formation of the adhesivecavity 38 by the interior and exterior blocks 34, 70 engaged with thestructural outer panel 10, an adhesive 24 is disposed within eachadhesive cavity 38 (step 408). The adhesive 24 is disposed tosubstantially fill each gap 22 and is contained in the adhesive cavities38 by the interior and exterior blocks 34, 70 and also by the interiorsurface 36 of the structural outer panel 10. The adhesive 24 is thencured to define a solid sealing member 44 within each adhesive cavity 38(step 410). The solid sealing member 44 adheres to the respectiveinterior block 34 and the interior surface 36 of the structural outerpanel 10 to form a sealed structural outer panel 10. After forming thesealed structural outer panel 10, the exterior blocks 70 are removedfrom the exterior surface 72 of the structural outer panel 10 (step412). Each solid sealing member 44 defines a hermetic seal at eachrespective gap 22. In order to form the structure of the door panel 12,a back panel 80 can be disposed onto the side edges 20 of the structuralouter panel 10 (step 414). In this manner, the back panel 80, structuralouter panel 10 and the solid sealing members 44 define an insulatingcavity 28 therein.

Referring now to FIGS. 1-10 , it is contemplated that the exteriorblocks 70 can be positioned against the exterior surface 72 of thestructural outer panel 10 and removed therefrom either manually, orthrough operation of a mechanical assembly 90 that engages each exteriorblock 70 to the exterior surface 72 of the structural outer panel 10.The mechanical assembly 90 can also remove the exterior blocks 70 afterthe adhesive 24 is cured to define the cured state 42 and the solidsealing member 44. The mechanical assembly 90 is a motorized system thatcan take several forms that can include, but are not limited to,operable arms 92, motorized actuators 94, levers, inflatable assemblies,rotating mechanisms, sliding mechanisms, combinations thereof, and othersimilar operable mechanisms that can be used to engage and disengage theexterior blocks 70 from the exterior surface 72 of the structural outerpanel 10. In this manner, each exterior block 70 is adapted to be reusedfor forming multiple sealed structural panels.

According to various embodiments, it is also contemplated that eachexterior block 70 can be formed by a multi-component assembly where afirst component engages one side edge 20 of the structural outer panel10 and another component of the exterior block 70 engages an adjacentside edge 20 to form the complete exterior block 70 proximate each gap22.

It is contemplated that during assembly, the metallic sheet 16 can bemoved into a forming portion of a mechanical assembly 90. Thismechanical assembly 90 can include folding members that serve to foldeach side flange 60 into the side edges 20 of the structural outer panel10. While in the mechanical assembly 90, operable members can place theinterior blocks 34, the exterior blocks 70 and also dispose the adhesive24 within the adhesive cavities. It is also contemplated that thestructural outer panel 10 can be formed through some manual operationsand some mechanically performed operations that are performed by themechanical assembly 90. An assembly line can also be used where varioussteps of the mechanical assembly 90 are used to perform the variousoperations for creating the insulated door panel 12 for the appliance14.

Referring again to FIGS. 1-10 , it is contemplated that an insulatingmaterial 26 can be disposed within the insulating cavity 28. Thisinsulating material 26 can be disposed therein before placement of theback panel 80 onto the side edges 20. The insulating material 26 canalso be placed within the insulating cavity 28 via an insulation portdefined within one of the back panel 80 and the structural outer panel10. In such an embodiment, insulation can be blown, poured, or otherwisedisposed within the insulating cavity 28 via the insulation port. Afterthe insulating material 26 is disposed therein, gas 30 can be expressedfrom the insulating cavity 28 via a gas port such that the insulatingcavity 28 defines an at least partial vacuum so that the door panel 12can define a vacuum insulated structure 32. It is also contemplated thatthe insulating material 26 can be in the form of a separate vacuuminsulated panel that is placed within the insulating cavity 28 beforethe back panel 80 is secured to the side edges 20 of the structuralouter panel 10. The insulating material 26 can also be a combination ofa vacuum insulated structure 32, such as a panel, and also additionalinsulating material 26 disposed within the insulating cavity 28.Combinations of these insulating materials 26 can also be used to definethe vacuum insulated structure 32 of the door panel 12.

Referring again to FIGS. 1-10 , it is contemplated that the interiorblocks 34 can be made of various materials. Such materials can include,but are not limited to, metals, plastics, polymer-based materials,composite materials, elastomeric materials, combinations thereof andother similar materials. By way of example, and not limitation, wherethe interior blocks 34 are made of a polymer-based material, suchmaterials can include polyvinyl chloride (PVC), polybutyleneterephthalate (PBT), liquid crystal polymer (LCP) or other similarmaterial having low permeation rates with respect to gasses and vapor.The exterior blocks 70 can be made of various materials that have lowadhesive properties so that the exterior blocks 70 can be easily reusedfor forming multiple structural outer panels 10. The materials of theexterior blocks 70 can include metal, elastomers, polymer-basedmaterials, composite materials, combinations thereof and other similarlow-adhesive materials. Where the exterior blocks 70 are made from apolymer-based material, one non-limiting example of such a material canbe polytetrafluoroethylene.

Referring again to FIGS. 1-10 , as discussed previously, the interiorblocks 34 are designed to remain within the insulating cavity 28, anddefine at least a portion of the insulating cavity 28 during the life ofthe door panel 12. Accordingly, the material of the interior block 34will typically have at least some insulating and/or sealing propertiesthat supplement the insulating material 26 and/or the solid sealingmembers 44 positioned at each gap 22 of the structural outer panel 10.

Referring again to FIGS. 1-10 , it is contemplated that the adhesive 24is a fast-curing adhesive 24. Additionally, the adhesive 24 can be inthe form of an encapsulating adhesive. Such encapsulating adhesive canbe a silicone-based adhesive, an epoxy-based adhesive, a compositeencapsulating material, combinations thereof, hybrids thereof and othersimilar adhesives 24 that can serve to quickly cure and form the solidsealing member 44 for hermetically sealing each gap 22 within thestructural outer panel 10. To assist in the fast-curing properties ofthe adhesive 24, various hardening agents, catalysts and other curingmaterials can be added to the adhesive 24. Additionally, the adhesive 24can be heated, cooled, dried or treated with another environmentalcondition to assist in the fast-curing nature of the adhesive 24.Additionally, the adhesive 24 and various components for curing theadhesive 24 can be disposed within the adhesive cavities 38 through useof an adhesive delivery system 100. This adhesive delivery system 100can be operated to deliver a predetermined amount of adhesive 24 intoeach adhesive cavity 38. A spray mechanism or pump 102 can be operatedto control the flow of adhesive 24.

Referring now to FIGS. 1-10 and 12 , a method 500 is also disclosed forforming a sealed structural outer panel 10 for an appliance 14.According to the method 500, a metallic sheet 16 is folded to define afront panel 18 and side edges 20 of the structural outer panel 10 (step502). Once folded into the structural outer panel 10, a gap 22 isdefined between each set of adjacent side edges 20. Typically, thestructural outer panel 10 will be a rectangular member such that fourgaps 22 are disposed between the four sets of adjacent side edges 20.After forming a structural outer panel 10, interior blocks 34 aredisposed proximate each respective gap 22 to define an adhesive cavity38 at each respective gap 22 (step 504). The positioning of eachinterior block 34 against the interior surface 36 of the structuralouter panel 10 at least partially forms the adhesive cavity 38. At thispoint in the process, each gap 22 is at least partially opened such thatthe insulating cavity 28 is not a fully defined space that caneffectively hold the adhesive 24. According to the method 500, exteriorblocks 70 are then disposed proximate each respective gap 22 in order tocomplete each adhesive cavity 38 (step 506). Each exterior block 70 istemporarily engaged with a respective set of adjacent side edges 20 tofurther define the adhesive cavity 38 at each gap 22.

Referring again to FIGS. 1-10 and 12 , once each adhesive cavity 38 isformed, the adhesive 24 is then disposed within each adhesive cavity 38(step 508). In this manner, the adhesive 24 substantially fills each gap22 and is typically a viscous material that can substantially fill eachadhesive cavity 38. The adhesive 24 is then cured to define a solidsealing member 44 that adheres to the respective interior block 34 andan interior surface 36 of the structural outer panel 10 (step 510).After the adhesive 24 is cured or at least substantially cured, theexterior blocks 70 can be removed from the exterior surface 72 of thestructural outer panel 10 (step 512). It is contemplated that theadhesive 24 must be substantially cured so as to define a substantiallysolid sealing member 44. The cured state 42 is defined, at minimum, by astate of the adhesive 24 that will not flow through the gap 22 definedbetween the adjacent side edges 20.

As discussed above, the exterior blocks 70 can be operated by amechanical assembly 90 that engages each exterior block 70 to theexterior surface 72 of the structural outer panel 10. The mechanicalassembly 90 can also remove the exterior blocks 70 after the adhesive 24reaches the cured state 42 to define the solid sealing member 44. It iscontemplated that the mechanical assembly 90 can include individualoperable arms 92 that are controlled by actuators 94 and have anexterior block 70 disposed at an end 110 of each respective operable arm92. Each operable arm 92 can be selectively operated by an actuator 94that manipulates and positions each exterior block 70 to be oriented ateach respective gap 22 of the structural outer panel 10. The moments ofeach operable arm 92 can include telescoping to extend and retract,rotation, sliding, twisting, combinations thereof and other similarmovements. It is also contemplated that the exterior blocks 70 can bemoved into an engaging position 112 that pushes against the exteriorsurface 72 of the structural outer panel 10 to define the minimal sealat each gap 22. This engaging position 112 can be a finite position thatis repeated for each structural outer panel 10 that is formed within themechanical assembly 90. Through the use of the mechanical assembly 90,the structural outer panel 10 can be made in a repeated dimensional andconsistent shape for each door panel 12. It is also contemplated thatthe operable arms 92 of the mechanical assembly 90 can be independentlyand selectively operated to engage the various gaps 22 that thosepositions may be slightly altered depending upon the shape of thestructural outer panel 10 placed within the mechanical assembly 90. Insuch an embodiment, the operable arms 92 can be at least partiallycontrolled by various sensors. Such sensors can include, but are notlimited to, pressure sensors, dimensional sensors, lasers, combinationsthereof and other sensors that can monitor the position of the exteriorblocks 70 with respect to the respective gap 22 and the side edges 20.

Referring now to FIGS. 1-10 and 13 , a method 600 is also disclosed forforming a vacuum structural outer panel 10 for an appliance door.According to the method 600, the metallic sheet 16 is folded to form astructural outer panel 10 that includes a plurality of side edges 20 anda gap 22 between each set of adjacent side edges 20 (step 602). Interiorblocks 34 are disposed proximate the interior surface 36 of thestructural outer panel 10 to define respective adhesive cavities 38(step 604). Temporary exterior dams, typically in the form of theexterior blocks 70, can be disposed at each gap 22 (step 606). Throughthe placement of the interior and exterior blocks 34, 70 or the interiorblocks 34 and the temporary exterior dams, each gap 22 is located withinone of the adhesive cavities 38 formed therein. The adhesive 24 can thenbe disposed within each adhesive cavity 38 to fill each gap 22 (step608). The adhesive 24 is then cured to define a solid sealing member 44that occupies each gap 22 within each respective adhesive cavity 38(step 610). The adhesive 24 in the cured state 42 serves to define thevarious solid sealing members 44 that hermetically seal each gap 22between the adjacent side edges 20. Each temporary exterior dam, orexterior block 70, is then removed from the exterior surface 72 of thestructural outer panel 10 (step 612). In this manner, the cured adhesive24 in the form of the solid sealing member 44 hermetically seals eachgap 22.

Referring again to FIGS. 1-13 , as a portion of each of the methods 400,500 and 600, completing the door panel 12 can include the additionalsteps of adding an insulating material 26 to an insulating cavity 28defined within the structural outer panel 10. The disposal of insulationcan be performed as substantially described herein. The timing of theinstallation can be various times throughout the formation of the doorpanel 12. By way of example, and not limitation, insulation can bedisposed before the back panel 80 is installed. Additionally, theinstallation can be installed after the back panel 80 is disposed on theside edges 20, where the insulation can be disposed through aninsulation port within the door panel 12.

The various methods 400, 500 and 600 can also include a step ofdisposing a back panel 80 onto the side edges 20 of the structural outerpanel 10 to define the enclosed structure of the door panel 12. In thismanner, the back panel 80, structural outer panel 10 and the curedadhesive 24 in the form of solid sealing members 44 can define aninsulating cavity 28 therein. As discussed above, this insulating cavity28 at the time of the placement of the back panel 80 can either befilled with insulation or can be filled with insulation after theplacement of the back panel 80. It is also contemplated that an outerfinish panel or veneer can be positioned over the structural outer panel10 to alter the outer aesthetic appearance of the door panel 12.

Referring again to FIGS. 1-13 , according to the various embodiments,the various aspects of the methods 400, 500 and 600 serve to use afast-curing adhesive 24 for placement within each adhesive cavity 38 forquickly forming the solid sealing member 44 for the structural outerpanel 10. The use of the removable exterior blocks 70 that can bemanipulated for the use of the mechanical assembly 90 serves to use thefast-curing properties of the adhesive 24 to more expediently form thesealed structure for the door panel 12. It is contemplated that theexterior blocks 70 can be removed before the adhesive 24 is completelycured. In such an embodiment, when the exterior blocks 70 are removed,the cured state 42 of the adhesive 24 does not flow through the minimalseam 74 defined by the gap 22 between the adjacent side edges 20.Additionally, the cured state 42 is sufficient to maintain thepositioning of each adjacent side edge 20 of the gap 22 to define theminimal seam 74 and prevent bending away of each adjacent side edge 20to expand the size of the gap 22 beyond that of the minimal seam 74.Additionally, because the interior blocks 34 are adapted to bepermanently installed within the structural outer panel 10, interiorportions of the adhesive 24 that may not be cured can be containedwithin the adhesive cavity 38 through the permanent placement of theinterior blocks 34. This configuration of the interior and exteriorblocks 34, 70 serves to afford more time for the adhesive 24 to curewithout maintaining the adhesive 24 and the structural outer panel 10within a specific molding assembly. The interior blocks 34 sufficientlydefine the mold of the adhesive cavity 38 to contain the adhesive 24long enough to completely cure without requiring that the structuralouter panel 10 be maintained within a single forming mold.

It will be understood by one having ordinary skill in the art thatconstruction of the described device and other components is not limitedto any specific material. Other exemplary embodiments of the devicedisclosed herein may be formed from a wide variety of materials, unlessdescribed otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of itsforms, couple, coupling, coupled, etc.) generally means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or with the twocomponents. Such joining may be permanent in nature or may be removableor releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement ofthe elements of the device as shown in the exemplary embodiments isillustrative only. Although only a few embodiments of the presentinnovations have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements shown as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures and/or members or connector or otherelements of the system may be varied, the nature or number of adjustmentpositions provided between the elements may be varied. It should benoted that the elements and/or assemblies of the system may beconstructed from any of a wide variety of materials that providesufficient strength or durability, in any of a wide variety of colors,textures, and combinations. Accordingly, all such modifications areintended to be included within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the desired andother exemplary embodiments without departing from the spirit of thepresent innovations.

It will be understood that any described processes or steps withindescribed processes may be combined with other disclosed processes orsteps to form structures within the scope of the present device. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can bemade on the aforementioned structures and methods without departing fromthe concepts of the present device, and further it is to be understoodthat such concepts are intended to be covered by the following claimsunless these claims by their language expressly state otherwise.

The above description is considered that of the illustrated embodimentsonly. Modifications of the device will occur to those skilled in the artand to those who make or use the device. Therefore, it is understoodthat the embodiments shown in the drawings and described above is merelyfor illustrative purposes and not intended to limit the scope of thedevice, which is defined by the following claims as interpretedaccording to the principles of patent law, including the Doctrine ofEquivalents.

What is claimed is:
 1. An insulated panel for an appliance, theinsulated panel comprising: a structural outer panel having a unitarymetallic sheet with a seam that is defined between adjacent folded sideedges that extend from a front panel; an interior block that is fixedlyattached to the adjacent folded side edges and positioned to at leastpartially define an adhesive cavity between the adjacent folded sideedges at the seam; a sealing member defined within the adhesive cavity,wherein the sealing member is a cured adhesive; and a back panelattached at least to the adjacent folded side edges of the structuralouter panel, wherein a continuous insulating cavity is defined at leastbetween the back panel, the structural outer panel, and the interiorblock.
 2. The insulated panel of claim 1, wherein the interior block ismade of a polymer-based material.
 3. The insulated panel of claim 1,wherein the cured adhesive is an encapsulating adhesive.
 4. Theinsulated panel of claim 1, wherein the cured adhesive is a compositeencapsulating material.
 5. The insulated panel of claim 1, wherein aninsulating material is disposed within the continuous insulating cavity.6. The insulated panel of claim 1, wherein the continuous insulatingcavity defines an at least partial vacuum.
 7. The insulated panel ofclaim 1, wherein the interior block is adhered to an interior surface ofthe structural outer panel.
 8. The insulated panel of claim 1, whereinthe interior block includes polybutylene terephthalate.
 9. The insulatedpanel of claim 1, wherein the interior block is attached to the backpanel.
 10. The insulated panel of claim 1, wherein an exterior surfaceof the structural outer panel and a portion of the sealing member, beinga solid sealing member, within the seam defines a continuous externalsurface that extends through each folded side edge of the structuralouter panel, the folded side edges including the adjacent folded sideedges.
 11. The insulated panel of claim 1, wherein the back panel ismetallic.
 12. A method of forming an insulated panel, the methodcomprising steps of: folding side flanges of a unitary metallic sheet todefine side edges of a structural outer panel, wherein the side edgesextend from a front panel and wherein a seam is defined between adjacentside edges of the side edges of the structural outer panel; securing theunitary metallic sheet within a form that includes exterior blocks;securing an interior block to an interior surface of the structuralouter panel and proximate the seam to define an adhesive cavity at theadjacent side edges that form the seam; disposing an adhesive within theadhesive cavity, wherein the adhesive fills a gap defined by the seamand is contained in the adhesive cavity by the form, the interior blockand the adjacent side edges; and curing the adhesive to a solid sealingmember within the adhesive cavity that adheres the interior block to theinterior surface of the structural outer panel to form a sealedstructural panel, wherein the solid sealing member occupies the gap; anddisposing a back panel onto the side edges of the structural outerpanel, wherein the back panel, the structural outer panel, and the solidsealing member at least partially define a continuous insulating cavitytherein.
 13. The method of claim 12, wherein the exterior blocks of theform are operable members that are operated by a mechanical assemblythat engages each exterior block to an exterior surface of the unitarymetallic sheet and removes the exterior blocks after the adhesive iscured to define the solid sealing member within each adhesive cavity.14. The method of claim 12, wherein the form is adapted to be reused forforming multiple structural outer panels.
 15. The method of claim 12,wherein the interior block remains adhered to the structural outer panelafter the adhesive is cured.
 16. The method of claim 12, wherein thestructural outer panel is removed from the form before the back panel isdisposed onto the side edges of the structural outer panel.
 17. A methodfor forming a vacuum insulated structure for an appliance, the methodcomprising steps of: disposing a folded metallic sheet within a form,wherein the folded metallic sheet defines a structural outer panelhaving a plurality of side edges and a seam between adjacent side edgesof the plurality of side edges; disposing an interior block proximate aninterior surface of the structural outer panel to define an adhesivecavity, wherein the seam is positioned within the adhesive cavity;disposing an adhesive within the adhesive cavity; curing the adhesive todefine a cured adhesive that occupies the seam within the adhesivecavity; and separating the folded metallic sheet from the form, whereinthe cured adhesive seals the seam in an air-tight configuration.
 18. Themethod of claim 17, wherein the interior block engages the interiorsurface of the structural outer panel at the adjacent side edges of theplurality of side edges.
 19. The method of claim 18, wherein the formincludes temporary exterior dams that are operated by a mechanicalassembly that engages each temporary exterior dam to an exterior surfaceof the structural outer panel and removes the temporary exterior damafter the adhesive is cured to define the cured adhesive.
 20. The methodof claim 19, wherein the mechanical assembly of the form includes afolding mechanism that operates to form a unitary metallic sheet intothe folded metallic sheet.